Mastic compositions



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comma a PLASTIC M w {ii UNITED STATES CROSS REFERENCE PATENT OFFICEMASTIC COMPOSITIONS Vilas E. Watts and Paul E. McCoy, San Francisco,

Calif., assignors to American Bitumals Company, San Francisco, Calif., acorporation of Delaware No Drawing.

18 Claims.

This invention relates to new and useful compositions of matter, moreparticularly to a setting composition for bituminous mastics and tomascs prepare erewith an e method of preparing them.

Asphalt and other similar bituminous substances possess well recognizedproperties which adapt them as constituents of cement or mastics forpaving, flooring compositions, molded articles, waterproofing compounds,and the like. Thus molten asphalt mixed with mineral dust, sandmopeghips has considerable am catiBrTa's" a mastic flooring composition.Asphalt floors thus made are warm under foot, tough, resilient, freefrom dust and therefore cleaner than concrete, and, since they can bedented but not chipped like concrete or stone floors, they are moreeasily maintained than the latter.

Hot mastic-type asphalt iioorings and the like have, however, certaindisadvantages. As stated, the asphalt is melted and mixed withaggregate. This necessitates a central heating plant to melt theasphalt, and sometimes to heat the aggregate.

It is, therefore, diflicult or not feasible to transport the heatedmaterials very far from the central heating plant, and, moreover, thepresence of such a heating plant creates a ilre hazard in confinedplaces in close proximity to combustible material, as below deck aboardships. Also, the hot mastic cools so quickly that it is extremelydiiiicult and often impossible to obtain a perfectly smooth floor orother surface free from corrugations; that is, the mastic sets quicklyto an uneven surface before it can be smoothed out.

"in these cold-lay mastics.

v Such mastics have the advantage that they can be mixed, laid andfinished at room temperature and therefore are more convenient to handlethan the hot mastics. However, they are in general slow in setting,requiring from 24 to 48 hours to set sufliciently to sustain foottraffic and ummous emulsion, aggregate and a Application November 16,1942, Serial No. 465,800

trucking. The cold-lay mastics also suffer from the disadvantage thatthe strength of the set mastic is governed'by the temperature andhumidity conditions prevailing during the setting period. Many suchmastics made using Portland cement as the setting agent have provedunsatisfactory for these and other reasons.

To obviate these difficulties various substitutes for Portland cementhave been offered to the trade. One such substitute is proposed inUnited ingredient or agent. As set forth in said patent,

and also in United States Patent No. 1,901,051 to Randel and Dailey,alpha gypsum is prepared by calcining ordinarygYpsum KQaSQ ZI-HO) in 20the firesegce of steam at a pressure of t 50 FcTu'fidETprefer'aLbly '17to pounds, per square inch gage, for 5 to 7 hours, meanwhile constantlyremoving water of condensation. Following the me sroauwn dried andground so that 85% or more passes through a IOU-mesh screen. This alphagypsum, as set forth in said patents, is much higher in compressive andtensile strengths than plaster of Paris, being like Portland cement inthis respect, whereas it sets quickly, viz. in 15 to 30 minutes, likeplaster of Paris. Its compressive strength is from 2500 to 5750 poundsper square inch and its pouring consistency is 50 cc. per 100 grams ofstucco, compared with a compressive strength of 1200 to 2500 pounds persquare inch and a pouring consistency of 52 to 96 cc. per 100 grams ofstucco for plaster of Paris. Also, crystals of this alpha gypsum, whenobserved under crossed nicols in I a petrographic microscope, are saidto appear rather short, thick and well formed and brilliantly colored.Chemically the alpha gypsum is distinguished from ordinary plaster ofParis by being a purer calcium s li fig. hemihgd t e g (ggsoi-tin o) g"In United States Patents Nos. 1,931,240 (Randel and Dailey) and1,979,704 (Randal, Bailey and McNeil) other methods of manufacturingalpha gypsum are described. I Alpha gypsum, however, suffers fromcertain disadvantagesas a setting agent for asphalt mastics and thelike. 'Thus, mastics made with it as the sole setting agent are brittleand cannot sustain suddenly applied loads. Upon the impact 72 to 96hours to set sumciently to sustain light 5 of a fallingjeight suchmastics are shattered EXAMINER i I i and cracked. Cracks so formed arenot selfknown to the art, although generally these will annealing, sincethe mastic is lacking in toughbe found unnecessary.

ness and resilience. Also, mastics made from The asphalt or otherbituminous emulsions 1 alpha gypsum suffer from the fact that they tendused with t e sai se ing mixture are prefera y i to be brown in colorrather than black and, thereof the stable mixing type. They may bestabilized fore, do not satisfy the demand of the trade for By any of avariety of stabilizing agents, notably I masticsof a rich,black"color.Vinsol resin (a product 0 e ercu es Powder D It is an object achieved bythe present inven- Company oBfiined by improved methods from tion toproduce a superior type of setting agent the wood of Southern long leai'pine, and dei" for mastics of the d-l t e. scribed and claimed as astabilizing agent for It is another object achieved by the presentinbituminous emulsions in Buckley, United States i vention to provideasphalt mastics and the like Patent No. 2,256,886); also Meadol," whichis a of the cold-lay type which set quickly to produce urified ligninproduct of 'f he Mead Corporasuperior floorings, patchwork, and thelike. 1011 and which is described in Industrial and It is a particularobject achieved by the pres- Engineering Chemistry, vol. 32, pages1399-1400 ent invention to provide asphalt mastics and the (1940).Clay-t stabilizers, such as bentonite like of the cold-lay type whichset quickly-to clay,-may 5E0 fie used to stabilize bituminous produce atough, resilient, substantially non- 'emulsions for use in the practiceor the present shrinking and non-cracking surface of rich blackinvention, as may still other types of stabilizer color. go ordispersing agent.

.Other objects achieved by the present invenvBesides asphalt, otherbituminous productsand tion will be apparentirom the description and ideed non-bituminous. water-EfiuBle'Thut the appendedclaims. ater-dis rsinces. such as na urai and We have .found that .mastics of greatlyimsynthetic resins,waxe ,.and syntheticrubbertii? proved characteristicscan bemade by using as 5 be'empioyed in making fioorfiig masBcswater- Cthe setting agent a mixture of alpha gypsumgifl proofing material,molded articles and the like in ?other H B-strength, uick-set ing forms01 ca accordance with the invention.

cineq gypsum and a hi h-alum na cement of the The selection of aggregatewill depend upon type represented by Lumnite cement. the requirements ofa particular Job and th types r Lumnite cement is defined in 0 men'sMaof aggregate available. Usually sand will be used,

0 Construction, 7th edition, page 358 also gravel where permissible medesirable (John Wiley and Sons), as an hydraulic cement for heavy dutyfloorings and the like. In cerconsisting essentially of alumina (A1203)40.0, tain cases, however, it b des W, lime (CaO) 40.0, iron oxides15.0, and silica, magheaggregate altogether. ofthere may be in- .nesia,insoluble material, etc., 5.0 per cent. It is animated-anthems variousother materials 1 stated by Johnson tobe manufactured from limesuch assawdust, cork dust, talc, asbestos, pigf stone and bauxite, either bythe dry process used ments anmke. r .inmaking 'Portland cement or byfusion in an Usually it will be necessary or desirable to add el ctrifurnace,.and tolbemuch darker colored water, in addition to that presentin the emul- ,than Portland cement. sion, to bring the mix to a suitablepouring and -We have foundthat by using Lumnite .cement trowelingconsistency. .along with alpha ypsum greatly and -un- The proportions ofthe various ingredients of Iexpectedly improved results are obtained.'This the mastic compositions or the present invention .invention,however, is not limited to the specific will vary'trom job to job. Forpurposes of guidcommercial products '.herein'above identified, alanceand illustration, however, the'followingfor- J though theyare preferred,but it includes the mulae are provided: A 3 r; production and employmentor mixtures oLhigh; (1 F M t fi ,i I .alurnina, high earlystrengthcements (sci-called 1 wfi falumlnoiis'cenihtm 'aiid'mgiist'iengtn, 12 1"Parts 4 setmrge sinnea'gyps s. Asphalt emu1sion ,,.m -I 7 'to2""Ithisberi ieimamt mastics prepared from Mastic setting powder 1mixtures of. such high-alumina cement and high Graded concrete-typedsand strength, quick-setting calcined gypsum, together .with asphaltemulsion and a gregate, set quickly, (2) For 11mg sustain foot trafi'cin less than six hours under 68 Parts almost any condition oftemperature and hu- Asphalt 6 %t02 midity, and sustain heavy traflic in12 to 24 hours. Mastic S g Powder '1 '.The mastic soi'ormed is notonly'hard and tough nd ea-1 but also has superior troweling qualitieswhen R001! chips thr ugh '%"'sieve "and on .freshlymade, sets veryrapidly, exhibits prac-oo 10 Sieve -4 'tically no shrinkage upon andafter setting, 'pos- .sessesa very. high compressive strength, is highly(3) 122 22 articles h resistant'to sudden shockas by impact 'of'aiall- RE g m we ght, and has a rich, uniform blackcolor. Asphfllt'emulsion 96 9In the high-alumina cement-a1 ha sum Mastic'settiflg Powder I Qmixturesof this invention. the proportions. ofinmesh smca igredients may varyfrom 1 partor less to'20 parts Chmmium Oxide E .ormore by volume oithecementto one part by V y 4) For insulation work volume of the alphagypswhough mixtures 9a 5 .containing sham ioparts' by volume oi'the h 1v rts N ement perpartby volumeoi alpha gypsum are fif i g g i' ggag -fpreierred. There may alsobe incorporated in j the setting mixture-smallamounts of set-retardvermiculate aggregate size- ,gzs ing or expar sinncontrolling agentsl u a hy- In the above formulae,'all parts are byvolume.

i ra ed ,lime P rt a c ment or ,dther seats 15 Also. it isintendedthatinieacfi'cas? sfifi'w'ater ous NaOH solution. These masticswere tested as set forth in Example Usually, the s1 ting mixture of theinvention 1. The compositions of the mastics and the test (high alumigacement and alpha gypsum or the results are given in Table II below. i

Table II 1 1 2 a 4 L fififilf t sah; by 1 ii 2 HydrocalA-H M 4 4 5 4 thy'2 i2 2 s2 Water m S? K K 56 Mixing flmiifl" Very plastic Very plasticPlastic Very plastic Troweling qualities Excellent Excellent SmoothExcellent Time for set to sustain ioot trailic 4 his 4 hrs. 4 hrs 4 hrs.Time for set to sustain light trucking 18 hrs. 18 hrs. 18 hrs. 18 hrs.Bali indentation in 12 hrs 0.6 0.65" 0.5" 0.6" Col Black Black BlackBlack like) will be dry mixed with gggregate, the dry All of theemulsions except No, 3 contained 1.7 mix dampene'dfbituminous emulsionad ed thercper cent by weight of Vinsol resin as a stabilizer. to aidmined and suificient wa er added to Emulsion No. 3 contained 1.2 percent by weight bring to the desired consistency. However, the of"Meadol" s stabilizer. a A hi h alumina ment and alpha sum maxim. WAmastic was formed in the usu agded e pggtely. an other variations withinthe way from 1, parts by volume of asphalt emulsion. scope of theinvention will be apparent to those 1 part by volume 01' a settinWdbfskilledin the art. 3 parts by volume of fifimriite cement and 1 part Thefollowing specific examples will serve to by weight of Hydrocal A-13)and 3 parts by illustrate the practice and advantages of the involume ofgraded concrete sand. Water was vention: added sufiicient to bring themix to a convenient Emampl Various mastics were made as fol- 4 trowelingconsistency. This mastic was used to lows: 1 part by volume of settingpowder was leakr j a large tank used for storage 0 mixed with 3% partsby volume of sand and the asphalt. The tank was of bolted sheetconstrucmixture was then mixed with 1% parts by volume tion with thejoints sealed by a rubber gasket oi asphalt emulsion. The asphaltemulsion was placed between the seams. In use the tank had composed of43 parts by weight of 0.32 per cent 45 developed leakage and to obviatethe same the aqueous NaOH solution, 55 parts by weight of tank wasemptied and the foregoing mastic was asphalt and 1.68 parts by weight ofVinsol resin applied over the seams. The mastic coating was as anemulsion stabilizer. Three difierent setting observed to dry rapidly andwas fit for use in 18 wwere used,asfollows: hour; 'I'lriethseainvgasperfect. Subsequent inspec on o e revealed no cracks and per- M Qgydrocal A43 feet adherence of the mastic to the metal walls 0 ortlandcement f the t nk d i h c. 20% HydrocalA-13+80%Lumnite cement a t e thatasphalt W (Percentages by weight) tained in the tank ranged intemperature from atmospheric to 300 F. Th y Variation in Pr ur in Pro Byincreasing the proportion pLLumnite cement Lumnitg gement and 1 partalpha gypsum by vol- Qume. The asp alt emulsion may comprise about equalparts by weight of asphalt and dilute aquegypsum is sold by the UnitedStates Gypsum Company er the trade name Mastical.

Ezampl Mastics were made usifig "Hydrocai A-13" and liumnite cement invarying proportions and using Vinsol resin and Meadol" as emulsionstabili e In all cases the emulsion war-mien of asphalt inaqueouiFaTiEtiE soda solution, the emulsion contaiiiih'bhiifiitwfie'i'ght tf asphalt based on the emulsion.

these various mastics was in the setting powder used. The followingresults were noted;

relative to alpha gypsum, greater toughness, 'quicEer settlligml'acfiercolor may be de- Table I i i Batting powder A B 0 Relative waterrequired for mixing 1 1.07..- 0.57. Handling properties. Smooth. easySmooth and Plastic mix. Good irow easy to handle. tro Time for set tosustain light loot trafllc. 6 hrs. 24 hrs. 3% hrs.Finalsettosustalnlighttrucking 24hr! 72h this. Shrinkage. N n BlightNegligible. Indentation after 72 hrs. 1.25" 1.05" 0.62". Color. Darkbrown... Dark brown..-.. Rich black color.

Thc indentation test consisted of resting s lilo-pound load on a 2-inchdiameter steel ball on the mastic after it had set (or 72 hours andmeasuring the diameter oi the indentation after 2 minutes oi loading.

The "H drocal A-13 of Example 1 and subsequent examples is the 't'fadename of a product of the United States Gypsum Company and it is a formof alpha gypsum. Another form of alpha veloped, whereas by increasingthe proportion of alpha gypsum. greater hardness and brittleness andslower setting qualities may be developed.

An outstanding advantage of the mastics or the present invention is thatthey set rapidly even under very adverse conditions, such as emperaturesof 32 F. and high humidity.

The mastics of the present invention may be employed for new floorings,patching old floors, refacing concrete flumes, dams and the like,filling cracks, damp proofing concrete walls, water proofing steelvessels, etc.

We claim:

1. A composition of matter, adapted to function as a setting agent formastics formed from aqueous bituminous emulsion and aggregate,comprising above 1 and not more than about 20 parts by volume ofaluminous cement and one part by volume of alpha gypsum.

2. A composition of matter, adapted to function as a setting agent formastics formed from aqueous bituminous emulsion and aggregate,comprising about 2 to parts by volume of aluminous cement and one partby volume of alpha gypsum.

3. A setting agent consisting substantially of 2 to 10 parts by volumeof Lumnite cement and about one part by volume of alpha gypsum.

4. A mastic-type composition, formed of substantial amounts each ofaluminous cement, alpha gypsum and an aqueous oil-in-water type emulsionof an organic substance selected from the group consisting of bitumens,waxes and resins.

5. A mastic-type composition, formed of substantial amounts each ofaggregate, aluminous cement, alpha gypsum and an aqueous oil-inwatertype emulsion of an organic substance selected from the group consistingof bitumens, waxes and resins.

6. The composition of claim 5, wherein said organic substance is abitumen.

'7. The composition of claim 5, wherein said organic substance isasphalt.

8. A hard, resilient masticadapted for flooring and the like, formed ofsubstantial proportions each of: an aqueous asphaltic emulsionstabilized with Vinsol resin; aggregate; and a mixture of about 1 to 20parts by volume of Lumnite cement to one part by volume of alpha gypsum,

9, The mastic of claim 8, where said alpha gypsum is Mastical."

10. In the method of preparing mastic-like compositions adapted to belaid cold wherein a bituminous emulsion is mixed with a setting agent,the improvement which comprises mixing the bituminous emulsion withaluminous cement and alpha gypsum as the setting agent.

11. The improvement of claim 10, wherein said cement is Lumnite cement.

12. In the method of preparing mastics wherein a bituminous emulsion,aggregate, a setting agent and water in quantity suflicient to bring themix to a suitable pouring and troweling consistency are commingled, theimprovement which comprises incorporating in the mix Lumnite cement andalpha gypsum as the setting agent.

13. Improvement of claim 12, wherein said bituminous emulsion is anasphaltic emulsion.

14. In the method of preparing mastics wherein an asphalt emulsionstabilized with Vinsol resin, aggregate, a setting agent and sumcientwater to bring the mix to a suitable pouring and troweling consistencyare commingled, the improvement which comprises incorporating in the mixLumnite cement and Mastical" as the setting agent.

15. A hard, resilient mastic adapted for flooring and the like, formedof substantial proportions each of: an aqueous asphaltic emulsionstabilized with "Meadol, aggregate and a. mixture of about 1 to 20 partsby volume of Lumnite cemerit to one part by volume of alpha gypsum,

16. A hard, resilient mastic adapted for flooring and the like, formedof substantial proportions each of: an aqueous asphaltic emulsionstabilized with clay, aggregate and a mixture of about 1 to 20 parts byvolume of Lumnite cement to one part by volume of alpha gypsum.

17. In the method of preparing mastics wherein an asphalt emulsionstabilized with Meadol," aggregate, a setting agent and suflicient waterto bring the mix to a suitable pouring and troweling consistency arecommingled, the improvement which comprises incorporating in the mixLumnite cement and Mastical as the setting agent.

18. In the method of preparing mastics wherein an asphalt emulsionstabilized with clay. aggregate, a setting agent and sufficient water tobring the mix to a suitable pouring and troweling consistency arecommingled, the improvement which comprises incorporating in the mixLumnite cement and "Mastical as the setting agent.

VILAS E. WATTS. PAUL E. MCCOY.

